Golf clubs prepared with basalt fiber

ABSTRACT

Golf club products include a shaft member and a club head body member engaged with the shaft member. At least some portion of this club head product is made from a basalt material. As some more specific examples, the basalt material may be used in one or more of: one or more layers of the shaft member structure; the entire shaft structure; a grip member; a hosel member; one or more parts of the club head body member, including any of: a crown member, a sole plate or member, a body member, a ribbon member (forming a portion of the body member), a face member, a ball striking face member, a weight member, etc.

BACKGROUND

Golf is enjoyed by a wide variety of players—players of differentgenders and players of dramatically different ages and skill levels.Golf is somewhat unique in the sporting world in that such diversecollections of players can play together in golf events, even in directcompetition with one another (e.g., using handicapped scoring, differenttee boxes, in team formats, etc.), and still enjoy the golf outing orcompetition. These factors, together with increased availability of golfprogramming on television (e.g., golf tournaments, golf news, golfhistory, and/or other golf programming) and the rise of well known golfsuperstars, at least in part, have increased golf's popularity in recentyears both in the United States and throughout the world. The number ofindividuals participating in the game and the number of golf courseshave increased steadily over recent years.

Golfers at all skill levels seek to improve their performance, lowertheir golf scores, and reach that next performance “level.”Manufacturers of all types of golf equipment have responded to thesedemands, and recently, the industry has witnessed dramatic changes andimprovements in golf equipment. For example, a wide range of differentgolf ball models now are available, with some balls designed tocomplement specific swing speeds and/or other player characteristics orpreferences, e.g., with some balls designed to fly farther and/orstraighter, some designed to provide higher or flatter trajectories,some designed to provide more spin, control, and/or feel (particularlyaround the greens), etc. A host of swing aids and/or teaching aids alsoare available on the market that promises to help lower one's golfscores.

Being the sole instruments that set golf balls in motion during play,golf clubs also have been the subject of much technological research andadvancement in recent years. For example, the market has seenimprovements in putter designs, golf club head designs, shafts, andgrips in recent years. Additionally, other technological advancementshave been made in an effort to better match the various elements and/orcharacteristics of the golf club and/or characteristics of a golf ballto a particular user's swing features or characteristics (e.g., clubfitting technology, ball launch angle measurement technology, ball spinrate characteristics, etc.).

Conventional golf clubs have three basic parts, a grip, a shaft, and ahead. As shown by the golf club 100 in FIG. 1, a grip 101 is attachedto/around the upper portion of shaft 102. The shaft 102 connects thegrip 101 to the head 103. The shaft 102 is held by the golfer and thehead 103 is the part that actually strikes the ball.

The golfer holds grip 101 of the golf club 100. With the exception ofgrips for putters, the grip 101 generally is round and generally withoutobvious bumps, lumps, or hollows. Grips can be made of any suitablematerial, generally polymers, rubber or leather, and can contain smallholes, grooves, ridges, cord elements, or fabric materials designed tomake it easier for the golfer to hold onto the club 100 without makingthe grip 101 so large that it will violate the Rules of Golf. There arevarious sizes of grips to accommodate different hand sizes and gripstyles. The material and design of the grip are generally a matter ofpersonal preference.

The shaft 102 of the golf club 100 connects between the grip 101 and thehead 103 and, like the grip, is basically round in cross section. Theshaft 102 may be a straight or generally a tapered tubular memberroughly, but not limited to, ½ inch in diameter (12 mm) near the grip,and generally between 18 and 48 inches (48-122 cm) (and typicallybetween 35 to 45 inches (89-115 cm) in length.

Most modern golf club shafts typically have been made of steel orfiber-reinforced resin composites utilizing fibers such as fiberglassand carbon or graphite fiber. Carbon fiber composites are lighter thansteel, but they tend to be more expensive. Some shafts utilize two ormore types of material, such as a graphite composite shaft with a steeltip.

FIG. 2 shows a conventional head 103 of a golf club. The typical head103 has several parts: the hosel 104, where the head 103 connects to theshaft 102; the face 105, which actually strikes the ball; the sole 106,which is the part closest to the ground; the back (not shown in FIG. 2),which is on the side opposite the face 105, and the top 109. The sides110 extend between the top 109 and the sole 106 at both the heel sideand the toe side of the club head 103. The face 105 may be formed toinclude a separate face plate, e.g., formed from metal, that is attachedto a framework defined by the remainder of the club head.

The head 103 of the golf club is where all the energy of the swing istransferred to the golf ball. There are a variety of different types ofgolf club heads, including, for example: the heads of woods, irons,wood-type hybrid clubs, iron-type hybrid clubs, and putters.

Woods or drivers have the largest heads of any golf club. Several ofthese large clubs are designed to propel the ball long distances, e.g.,300 yards or more with a single swing. The large head of a driver orother woods and the materials from which they are made, such as metals(e.g., steel, titanium, aluminum, and bronze), fiberglass reinforcedresin composites, or carbon fiber-reinforced resin composites, arebalanced to provide stability and light weight. The driver or wood headshape, including wood-type hybrid club heads, allows the weight in thehead to move to points that enhance stability. The driver or wood headshape also allows the head to glide over grass and ground rather thandigging into the turf.

Irons are designed for a greater variety of shots than woods. Woods ordrivers tend to be optimal for long to very long shots, whereas ironsare used for shots that range from less than 300 yards down to 40 yardsor less. Relatively recent developments with perimeter weighting andcavity back designs have made irons more “forgiving” and easier for theaverage golfer to hit.

Putters are designed to strike the golf ball with a face that issubstantially perpendicular to the intended ball path with a relativelygentle swing that will cause the ball to roll along the ground until itstops or falls into a hole. Putter heads may be found in a wide array ofshapes—blocks, blades, short, long, thick, thin, etc., optionally withvarious patterns of lines found on the faces or even smooth faces.

The “number” or name associated with a club generally is related to theangle at which the face 105 slopes back from vertical when the club isheld in its normal position facing the ball. A higher number for theclub represents a greater degree of slope away from vertical, generallyresulting in a higher, shorter shot as compared with lower numberedclubs.

The slope is important for propelling a golf ball with the desiredtrajectory through the air and for imparting spin. Typically, thegreater the slope, the greater the spin. A rapid spin providesaerodynamic lift, causing a spinning ball to travel higher and fartherthan one with no spin at all. The spinning ball is also less influencedby small gusts of wind, making for a more predictable shot. Grooves inthe face 105 will also help provide spin.

The grooves on the face of a golf head provide a bit of “bite” orfriction for the golf ball as it slides up the face, helping it to spinmore rapidly. In addition, if grass is trapped between the ball and clubat impact, the water in the grass will be squeezed out by the forcegenerated by the average swing. Similar to an automobile tire tread, thegrooves on the club face give the water somewhere to go so that the balldoes not skid up the club face without spinning.

Ideally, the sole of the golf club will help minimize the twisting of apoor swing. Woods and wood-type hybrid clubs have a relatively broad,flat sole with rounded edges to help the head glide over the surface ofthe grass without digging into the turf. Irons, on the other hand, tendto be hit so as to produce divots in the turf, so the soles of iron golfclubs (including iron-type hybrid clubs) typically are designed to slicethrough the turf evenly, without twisting or unexpected tugging todisrupt the golfer's shot.

It is known to use fiber-reinforced resin composites in the constructionof golf club shafts. Such reinforcing fibers include carbon fiber,polyamide fiber, glass fiber, boron fiber, alumina fiber, aramid fiber,Tyranno™ fiber, and amorphous fiber. The fiber-reinforced resincomposite may be used in layered structures, molded structures, andcombinations thereof. Examples of the variety of uses of fibers in theconstruction of golf club shafts include, but are not limited to, thosedescribed in U.S. Pat. Nos. 4,157,181; 6,354,957; and 6,572,490; andU.S. Patent Publication No. 2005/0107182. Each of these documents isentirely incorporated herein by reference.

Carbon fiber composite materials also are known for use in golf clubheads, including, for example, as part of the crown or body of awood-type club head structure. Examples of patents illustrating suchcarbon composite containing club head structures include: U.S. Pat. Nos.6,491,592 and 6,739,982. These patents also are entirely incorporatedherein by reference.

Carbon fiber is particularly preferable and used in golf club heads andgolf club shaft structures due to its superior strength and modulus, orstiffness. Carbon fiber, however, is expensive and may be costprohibitive. Fiber glass is a low cost alternative to carbon fiber, butit has physical properties inferior to carbon fiber. Thus, a low costalternative to carbon fiber would be desirable.

SUMMARY

This invention relates to golf clubs having heads and shafts, such asputters, irons (including all types of wedges), hybrid type clubs (bothiron-type hybrid clubs and wood-type hybrid clubs), fairway woods,drivers, and the like. One aspect of the invention is the use of basaltmaterial, in particular basalt fiber, in the design of composite golfclub shafts and heads. Basalt fiber is superior to fiber glass,approaching the performance of carbon fiber materials, but at a muchlower cost.

Golf clubs and golf club heads according to at least some exampleaspects of this invention may include: (a) a club shaft memberconstructed, at least in part, from basalt material and/or (b) a clubhead body member constructed, at least in part, from a basalt material.Optionally, if desired, the club shaft member and/or the club head bodymember may be of a multi-piece construction, and any one or more ofthese multiple pieces may be formed from a basalt material withoutdeparting from this invention.

Additional aspects of this invention relate to methods of making and/orusing golf club shafts and/or golf club heads that include basaltmaterial forming at least a portion of the club shaft and/or club headstructure.

Another aspect of the invention relates to a light weight, optionallytapered, tubular structure that provides superior performance for a widevariety of applications, especially in golf club shafts, but also inother products such as fishing rods, ski poles, knitting needles,croquet mallets, racquets, bats, billiard cue sticks, tools, toolhandles, etc.

DESCRIPTION OF THE DRAWINGS

The foregoing Summary, as well as the following Detailed Description,will be better understood when read in conjunction with the accompanyingdrawings.

FIG. 1 depicts a typical golf club having a grip, shaft and head.

FIG. 2 depicts a typical golf club head.

FIG. 3 depicts a putter type golf club.

FIG. 4 depicts an iron type golf club head.

FIG. 5 depicts a wood-type golf club head.

FIGS. 6 through 6 c depict various features of an elongated tubularstructure for various potential products according to the invention.

DETAILED DESCRIPTION I. General Description of Aspects of the Invention

The following description and the accompanying figures disclose featuresof golf club shafts and golf club heads in accordance with the presentinvention (e.g., woods, irons, hybrids, putters, etc.). Various examplesof the use of basalt materials in golf club head and shaft structures inaccordance with aspects of the present invention will now be described.However, the invention is not limited to any particular design of thegolf club shaft or heads.

Generally, in accordance with at least some example aspects of thisinvention, basalt material is used to replace metal in an overall clubshaft or head structure to save weight (e.g., basalt fibers in a resinmatrix typically are lighter than the same volume of metal, but theresulting basalt fiber-reinforced composite material remains strong). Ina golf club head structure, for example, this “saved” weight can bemoved to various desired locations in the club head structure, e.g., tothe back and bottom sides of the club head structure, which improves theperformance of the club to strike the golf ball well with improvedaccuracy and farther distance or helps the club's “hit-ability” (a lowerand deeper center of gravity helps golfers get the ball airborne andhelps prevent club head twist [increasing club head moment of inertia]);to the toe side of the club head structure (to provide a fade biasedand/or hook correcting club head structure); to the heel side of theclub head structure (to provide a draw biased and/or slice correctingclub head structure); around the club head perimeter; etc.

In general, the basalt material can be used in a wide variety oflocations in a club structure (e.g., as a basalt fiber-reinforcedcomposite material). For example, in accordance with at least someexamples of this invention, basalt fibers will be used to form at leasta portion of the club head body (e.g., often engaged with a steel,aluminum, magnesium, or titanium alloy used as the face member). Thebasalt material can be used, for example, as at least a portion of oneor more of a crown member, a sole member, and/or a skirt or ribbonportion of the club head. In many instances, the entire rear portion ofthe club head (e.g., its “aft body” rearward from a face member) will bemade from the basalt material (e.g., attached to a metal [e.g., a steel,aluminum, magnesium, or titanium metal or alloy material] face cupincluding the ball striking surface). Club heads also could have abasalt material face plate member (e.g,, as the ball striking face, as aframe member for holding a separate ball striking face, etc.). In oneparticular aspect of the invention, the basalt material may be used in awood or hybrid type golf club structure, such as in a driver, fairwaywood, and/or wood-type hybrid club head structure.

Alternatively, if desired, the entire club head may be made of basaltmaterial, e.g., in the form of a basalt fiber reinforced resincomposite, which may be formed into the proper configuration by anydesired method, including by conventional fiber-reinforced materialproduction techniques that are known and used in the art (e.gcompression molding, resin transfer molding RTM, vacuum assisted resintransfer molding VARTM, prepreg lay up, etc.). A metal cover or ballstriking plate may cover the face or fit into an opening provided in theface, if desired.

Various examples of the production of golf clubs and other structures,including structures according to the present invention and resultsobtained using such structures, are provided below. Those skilled in theart will recognize, however, that the scope of the present invention isin no way limited to these examples or the results achieved thereby.

II. Detailed Description of Example Golf Club Heads and Other StructuresAccording to the Invention

A. Basalt—Basalt Fibers—Reinforced Resins

Generally, basalt is a hard, dense, dark volcanic rock composed chieflyof plagioclase, pyroxene, and olivine, and often has a glassyappearance. Basalt has been mainly used as a crushed rock inconstruction, industrial and highway engineering. Basalt also can bemade into fine, superfine, and ultra fme fibers. Techniques for makingor spinning basalt into fibers are known in the art.

Basalt fibers are superior to many other fibers in terms of thermalstability, heat and sound insulation properties, vibration resistance,and durability. Basalt fiber products, for example, can provide very lowthermal conductivity and can withstand working temperatures in excess of816° C. Moreover, products made with basalt fibers have no toxicreaction with air or water, are non-combustible, explosion proof, andhave a long service life. When in contact with other chemicals, basaltfibers produce no chemical reactions that may damage health, theenvironment, or the general structural integrity of the constructioninto which the basalt fiber is built. Basalt is both alkali and acidresistant.

Basalt fibers also provide good tensile strength in products. Forexample, basalt reinforcement rods made of a unidirectional composite ofbasalt fibers, used to replace steel rebar, can have a tensile strengthof 1200 MPa.

Basalt may be in the form of continuous or discontinuous fibers,particles, flakes, whiskers, filaments, ribbons, and rods. Basaltfibers, for example, generally can have diameters from approximately 9μm to 23 μm. Discontinuous or chopped basalt fibers, for example,generally can have a length of 1 cm to 5 cm.

Basalt material may also be produced in the form of sheets, mats, felts,grids, meshes, woven members, braided members, lattice network members,textiles, or mixtures thereof prepared from, for example, continuous ordiscontinuous fibers, particles, flakes, whiskers, filaments, ribbons,rods and combinations thereof.

The invention will be generally described in terms of use of “basaltmaterial,” which is intended to refer to any suitable form of basalt,including, but not limited to: basalt fibers: basalt fiber-reinforcedmaterials (such as polymers, metals, composite materials, and the like):structures containing basalt in the form of sheets, mats, felts, grids,meshes, woven members, braided members, lattice network members,textiles, or mixtures thereof; and the like.

In a particular aspect of the invention, the basalt material is combinedwith a suitable polymer matrix to form a basalt reinforced polymercomposite. As a more specific example, the basalt is used in the form offibers to produce a basalt fiber-reinforced product by incorporatingbasalt fibers into a suitable polymer matrix.

Any desired polymer matrix or base material may be used and reinforcedwith basalt materials, including basalt fibers, without departing fromthis invention. For example, the polymer matrix may comprise:thermosetting resins, such as epoxy resins, phenol or urea formaldehyderesins, polyurethane resins, polyester resins, vinyl ester resins andthe like; and thermoplastic resins, such as polypropylene resins,polyether ether ketone resins, acrylonitrile-butadiene-styrene resins,nylon resins, etc. Other examples include, but are not limited to,polyphenylene sulfide, polysulfone, polyethylene terephthalate, andpolycarbonate resins.

Prior to mixing with the polymer matrix, the basalt fibers can betreated or coated with a chemical sizing or treated to modify surfaceenergy, e.g., to make them more compatible with the polymer matrix. Thesizing treatment may include, for example, coating with epoxy orphenolic resins, treating with acid, atmospheric plasma, coronadischarge, or the like.

The invention will be generally described in terms of a resin, but anysuitable polymer matrix may be used. Basalt fibers, for example, aremixed with the resin so as to form a basalt fiber-reinforced resincomposition. Generally the reinforcement composition in the resin matrixmay range from 5 wt % to 70 wt % reinforcement or approximately 2 vol %to 50 vol % reinforcement. Generally more preferred the reinforcementcomposition in the resin matrix may range from 30 wt % to 50 wt %reinforcement or approximately 13 vol % to 27 vol % reinforcement,depending on the performance requirements of the application and theform of the basalt material including, for example, sheets, mats, felts,grids, meshes, woven members, braided members, lattice network members,textiles, or mixtures thereof prepared from, for example, continuous ordiscontinuous fibers, particles, flakes, whiskers, filaments, ribbons,rods and combinations thereof Carbon Carbon Property Units BasaltE-Glass low cost high modulus Density (g/cm3) 2.75 2.6 1.8 1.9 Tensilestrength (MPa) 4840 3450 2890 2750 Elastic modulus (GPa) 89 77 230 390

The basalt fiber-reinforced resin composition may then be formed intothe head of a golf club, the shaft of a golf club, or into a tubularmember. The basalt fiber-reinforced composite may form all or part ofthe shaft, head, and/or other member, as known in the art for use ofother fiber-reinforced resin composites, such carbon fiber- andfiberglass-reinforced composites.

In view of the above description of basalt materials, more specificexamples of golf club structures and other structures according to theinvention incorporating such composites are provided below.

B. Example Head Structures

Golf club heads according to at least some example aspects of thisinvention may include a club head body member constructed, at least inpart, from basalt material. Generally, in accordance with at least someexamples of this invention, at least a portion of the club head may bemade from basalt material. For example, the head may be formed entirelyor partially from a basalt material. Any or part of one or more of thehosel, face, sole, back, crown, top, and sides of the club head,including the ball striking face and/or a frame for holding the ballstriking face, may be formed entirely or partially of a basalt material.Such heads may be constructed in any suitable manner, including, forexample, in conventional manners known and used in the art for formingclub heads or portions thereof from prior art fiber-reinforcedcomposites (such as carbon-fiber reinforced materials). As some morespecific examples, if desired, the club head may be formed to includeone or more of a crown member, a skirt member, a ribbon member, an aftbody member, a face cup or other face member, a hosel member, a soleplate member, a ball-striking member, etc. from a basalt material (e.g.,a basalt fiber-reinforced material). The parts of the head may bemanufactured by integrally forming one or more of these parts as aunitary, one-piece construction; by forming multiple, separate parts andjoining them together, e.g., using an adhesive, cement, mechanicalconnectors, fusing techniques, etc.; or the like.

1. Putter Structures

One example aspect of this invention relates to putter structures thatinclude one or more parts made, at least in part, from basalt material.

FIG. 3 illustrates an example of parts for a putter structure 300 thatmay be made from basalt material in accordance with at least someexamples of this invention. The head member 302, as illustrated in FIG.3, includes a face member 304 that faces a golf ball (or other ball)when the club head is used. The body member 302 in this illustratedexample essentially is rectangular cubic shaped such that a back member306 is located opposite the face 304. Of course, a wide variety ofsizes, shapes, and orientations of body member 302 and/or other putterhead designs may be used without departing from the invention,including, for example, mallet type putter heads, blade type butterheads, etc.

Basalt material may be used for part of or the entirety of the head. Forexample, basalt material may be used in face member 304, back member306, and/or shaft mounting member (hosel member) 312. The body member302 may be made of basalt material and a faceplate, e.g., a metal orpolymeric ball striking face piece, may be attached to the face member304.

If desired, in accordance with at least some examples of the invention,the club head 302 may include weighted regions, e.g., located in therear and/or toward the heel and toe regions of the club head 302.Weighted regions of this type can assist in increasing the club head'smoment of inertia, thereby reducing club head twist during a swing. Ofcourse, the weighted regions may be provided in any desired mannerwithout departing from the invention, e.g., by attaching one or moreseparate weight elements to the club head structure (e.g., in weightreceiving receptacles), by integrally forming the weighted region intothe remainder of the club head structure, by applying lead tape or otherweighted adhesive material, by plasma spraying, etc.

Also, the weighted regions may be provided in either or both of the clubhead's interior or exterior structure without departing from thisinvention.

Any desired type of shaft member 310 may be used in the putter structure300 without departing from the invention, including shaft members 310 ofconventional design and made of conventional materials as are known andused in the art, including, for example, steel, titanium, aluminum,nickel, tungsten, magnesium, graphite, polymers, or composites, orcombinations thereof (including alloys of the various metals notedabove). Alternatively, if desired, either or both of the hosel or othershaft mounting member 312 and/or the shaft member 310 may be made, atleast in part, from a basalt material.

A grip element 314 may be positioned on the shaft 310 to provide agolfer with a slip resistant surface with which to grasp golf club shaft310. The grip element may be attached to the shaft member 310 in anydesired manner, including in conventional manners known and used in theart (e.g., via adhesives or cements, mechanical connectors, etc.).

As noted above, basalt materials, including basalt fiber-reinforcedmaterials may be used in any type of putter structure, including, forexample, one or more of the various parts of the example puttersillustrated in U.S. Published Patent Appln. No. 2006/0052178, whichdocument is entirely incorporated herein by reference.

2. Example Iron Type Golf Club Structures

Putters are not the only types of golf clubs that can take advantage ofthe weight saving and other favorable properties of basalt materials.These materials also can be used, for example, in iron type golf clubstructures. Referring to FIG. 4, a golf club 400 in accordance with atleast some examples of this invention is illustrated. This example golfclub 400 includes a shaft member 410 and a golf club head member 402.

The golf club head member 402 of FIG. 4 may be representative of anyiron or hybrid type golf club head, including, for example, 0 through 10irons, pitching wedges, lob wedges, gap wedges, sand wedges, iron-typehybrid clubs, etc..

The shaft member 410 of golf club 400 may be made of various materials,such as one or more of steel, titanium, graphite, or compositematerials, as well as combinations thereof, including materials that areconventionally known and used in the art. As another example, ifdesired, the shaft member 410 may be made, at least in part, from abasalt material. Additionally, the shaft member 410 may be attached tothe club head 402 in any desired manner, including in conventionalmanners known and used in the art (e.g., via adhesives or cements at ahosel element 412 (which itself may be made, at least in part, from abasalt material), via threads or other mechanical connectors, etc.).

A grip element (not shown but similar to the grip shown in FIG. 3) maybe positioned on the shaft member 410 to provide a golfer with a slipresistant surface with which to grasp golf club shaft member 410. Thegrip element may be attached to the shaft member 410 in any desiredmanner, including in conventional manners known and used in the art(e.g., via adhesives or cements, mechanical connectors, etc.).

As shown in FIG. 4, the golf club head 402 includes a heel portion 408and a toe portion 404. The heel portion 408 is attached to and/orextends from a hosel 412 (e.g., as a unitary or integral one-piececonstruction) for connecting the shaft member 410 to the golf club head402. The golf club head 402 also includes a top portion 414 and a soleportion 416. A striking face 418 is provided between the top portion 414and the sole portion 416, and between the toe portion 404 and the heelportion 408.

The striking face 418 provides a contact area for engaging andpropelling a golf ball in an intended direction. The striking face 418may include grooves 420 (e.g., generally horizontal grooves 420extending across the face 418 in the illustrated example) for theremoval of water and grass from the striking face 418 during a ballstrike. Of course, any number of grooves and desired groove pattern maybe provided (or even no groove pattern, if desired), without departingfrom this invention.

The golf club head 402 may be constructed from a wide variety ofdifferent materials, including materials known and used in the art, suchas steel, titanium, aluminum, nickel, tungsten, magnesium, graphite,polymers, or composites, or combinations thereof (including alloys ofthe various metals noted above). Advantageously, in accordance with atleast some examples of this invention, at least some portion of the clubhead structure (e.g., a major body portion thereof) will be formed froma basalt material. Also, the club head 402 may be made from any numberof independent pieces and/or by any construction technique, including,for example, casting, forging, and/or other methods known and used inthe art.

The striking face 418 may be formed from a separate face plate attachedto the club head 402 as is known in the art by any desired manner, e.g.,fabricated as a one piece construction; welded, brazed, or solderedthereto; bonded thereto with cements or adhesives, etc.; coated orfilled therein (e.g., as a molten metal or polymer coating or filling,etc.); etc. Also, the face plate may be made from the same or adifferent material as compared with the materials used for other partsof the club head 402. In at least some examples of this invention, theface plate 418 and/or a frame member to which it is attached (e.g.,forming at least a portion of the club head body 402) may be formed froma basalt material, such as a basalt fiber-reinforced material.

The use of basalt materials for at least some portions of the golf clubhead 402 or other portions of the golf club structure (such as hosel 412or shaft member 410) can assist in club design by enabling clubdesigners and manufacturers to selectively place weight and move thecenter of gravity to positions so as to better affect the ball flight.For example, positioning the center of gravity of the club head 402 awayfrom the striking face 418 and toward the rear of the golf club head 404may better conform to the play characteristics, style, and preferencesof many golfers.

If desired, in accordance with at least some examples of this invention,weighted regions may be provided at one or more locations in the overallclub head structure, e.g., around the club head perimeter, at a low,rearward position, in the club toe area 404, in the club heel area 408,along the club sole 416, etc. Weighting of this type can help increasethe club head's moment of inertia characteristics and/or help modify theball flight, e.g., in the various manners described above and in themanners known in the art. Of course, the weighted regions may beprovided in any desired manner without departing from the invention,e.g., by attaching one or more separate weight elements to some portionof the club head structure (e.g., in weight receiving receptacles), byintegrally forming the weighted region into the remainder of the clubhead structure, by applying lead tape or other weighted adhesivematerial, by plasma spraying, by providing a rear “bridge member” asused in commercially available SLINGSHOT® iron products available fromNIKE, Inc., of Beaverton, Oreg., by including one or more weights on abridge member, etc. Also, the weighted regions may be provided in eitheror both of the club head's interior or exterior structure withoutdeparting from this invention.

Again, as noted above, basalt materials, including basaltfiber-reinforced materials, may be used in any desired iron golf clubstructure, including cavity back clubs, perimeter weighted clubs, muscleback clubs, blade-type clubs, and the like. As some more specific andnon-limiting examples, basalt materials may be used as one or more partsof the club head structures illustrated, for example, in U.S. Pat. No.6,918,840; U.S. Pat. No. 6,981,924; and U.S. Patent Publication No.2005-0137024. Each of these documents is entirely incorporated herein byreference.

3. Example Wood Type Golf Club Structures

Aspects of this invention are not limited to use with putters, irons,and/or hybrid iron type golf clubs and golf club heads. FIG. 5illustrates an example of a golf club 500 in accordance with at leastsome examples of this invention. Notably, the overall golf clubstructure 500 of this example includes a golf club head 502, a hoselregion 512, a shaft member 510 received in and/or inserted into and/orthrough the hosel region 512, and a grip or handle member (not shown)attached to the shaft member 510. Optionally, if desired, the hoselregion 512 may be eliminated and the shaft member 510 may be directlyinserted into and/or otherwise attached to the head member 502 (e.g.,through an opening provided in the top and optionally bottom of the clubhead 502). Optionally, if desired, the hosel member may be locatedinternal to the club head structure 502.

The shaft member 510 may be received in, engaged with, and/or attachedto the club head 502 in any suitable or desired manner, including inconventional manners known and used in the art, without departing fromthe invention. As more specific examples, the shaft member 510 may beengaged with the club head 502 via the hosel member 512 or directly withthe club head structure 502, e.g., via adhesives, cements, welding,soldering, mechanical connectors (such as threads, retaining elements,or the like), through a shaft-receiving sleeve or element extending intoand/or within the club head body 502, etc. The shaft member 510 also maybe made from any suitable or desired materials, including conventionalmaterials known and used in the art, such as graphite based materials,composite materials, steel materials (including stainless steel),aluminum materials, titanium materials, magnesium materials, other metalor metal alloy materials, polymeric materials, combinations of variousmaterials, and the like. If desired, either or both of the shaft member510 and the hosel member 512 (when present) may be made from a basaltmaterial.

The grip or handle member (not shown) may be attached to, engaged with,and/or extend from the shaft member 510 in any suitable or desiredmanner, including in conventional manners known and used in the art,e.g., using adhesives or cements; via welding, soldering, adhesives, orthe like; via mechanical connectors (such as threads, retainingelements, etc.); and/or in any other desired manner. As another example,if desired, the grip or handle member may be integrally formed as aunitary, one-piece construction with the shaft member 510. Additionally,any desired grip or handle member materials may be used withoutdeparting from this invention, including rubber materials, leathermaterials, rubber or other materials including cord or other fabricmaterial embedded therein, polymeric materials, metal materials, and thelike. The grip or handle member also may be made, at least in part, froma basalt material.

The club head 500 may be constructed in any suitable or desired mannerand/or from any suitable or desired materials without departing fromthis invention, including in conventional manners and/or fromconventional materials known and used in the art. For example, in theexample structure shown in FIG. 5, the club head 502 includes a solemember 507, a face member 508, at least one body member 509, and a crownmember 511. The body member(s) 509 may be formed, for example, as bandsor ribbons of material (e.g., optionally generally U-shaped bands orribbons) that extend around from one side of the face member 508 to itsother side and form at least a portion of the perimeter of the middle ofthe golf club head body 502 (e.g., such that the overall club headstructure 502 defines an at least partially hollow interior chamber(e.g., into which the shaft member 510 may be inserted and/or secured)).Any of the individual portions of the club head structure 502 describedabove may be made from multiple independent pieces, and/or two or moreof these individual portions may be integrally formed together, e.g., asunitary, one-piece constructions, without departing from this invention(e.g., the sole and/or crown members additionally may form at least someportions of the club head body and/or face members, etc). As otheroptions, if desired, the overall club head structure 502 may becomprised of a single, one-piece construction (optionally hollowed out)or the face member 508 may attach to a one or more piece club head “aft”body, etc.

The various individual parts that make up a club head structure 502, ifmade from multiple pieces, may be engaged and/or held together in anysuitable or desired manner, including in conventional manners known andused in the art. For example, the various parts of the club headstructure 502 may be joined and/or fixed together (directly orindirectly through intermediate members) by adhesives, cements, welding,soldering, or other bonding or fusing techniques; by mechanicalconnectors (such as threads, screws, nuts, bolts, or other connectors);and the like. If desired, the side edges of various parts of the clubhead structure 502 (e.g., the edges where sole member 507, face member508, body members 509, and/or crown member 511 contact and join to oneanother) may include one or more raised ribs, tabs, ledges, or otherengagement elements that fit into or onto corresponding grooves, slots,surfaces, ledges, or openings provided in or on the facing side edges towhich they are joined. Cements, adhesives, mechanical connectors, or thelike may be used in combination with the raised rib/groove or otherconnecting structures described above to further help secure the variousparts of the club head structure 502 to one another.

In at least some examples of the invention, the materials making up atleast some of the various portions of the club structure 500 (e.g., atleast some potion(s) of the sole 507, the face plate 508, the bodymember(s) 509, the crown 511, the hosel 512, the shaft 510, etc.) may beformed from a basalt material, e.g., like the various materialsdescribed above. If desired, two or more of these parts may beintegrally formed as a one-piece construction (e.g., if desired, thesole 507, the body member 509, and/or the crown 511 may be integrallyformed as one piece with a separate face plate member engagedtherewith). Also, any desired materials may be used for various portionsof the club head body 502 without departing from the invention,including, for example, aluminum, nickel, titanium, steel, polymers,glasses, ceramics, rubbers, and/or combinations thereof. When at leastsome portion of the club head structure 502 is formed from a basaltmaterial, if desired, the shell wall thickness may be made somewhatlarger than the shell members of many conventional club heads, such asmetallic shell walls.

The use of basalt materials for at least some portions of the golf clubhead 502 or other portions of the golf club structure (such as hosel 512or shaft member 510) can assist in club design by enabling clubdesigners and manufacturers to selectively place weight and move thecenter of gravity to positions so as to better affect the ball flight.For example, positioning the center of gravity of the club head 502 awayfrom the striking face 508 and toward the rear and lower portions of thegolf club head 502 may better conform to the play characteristics,style, and preferences of many golfers.

If desired, in accordance with at least some examples of this invention,weighted regions may be provided at one or more locations in the overallclub head structure 502, e.g., around the club head perimeter, at a low,rearward position, in the club toe area, in the club heel area, alongthe club sole 507, along the club body member 509, etc. Weighting ofthis type can help increase the club head's moment of inertiacharacteristics and/or help modify the ball flight, e.g., in the variousmanners described above and in the manners known in the art. Of course,the weighted regions may be provided in any desired manner withoutdeparting from the invention, e.g., by attaching one or more separateweight elements to some portion of the club head structure (e.g., inweight receiving receptacles), by integrally forming the weighted regioninto the remainder of the club head structure, by applying lead tape orother weighted adhesive material, by plasma spraying, by providingmovable and/or removable weights, etc. Also, the weighted regions may beprovided in either or both of the club head's interior or exteriorstructure without departing from this invention.

The dimensions and/or other characteristics of a wood-type golf clubhead structure according to examples of the invention may varysignificantly without departing from the invention. Moreover, anydesired type of wood-type golf club head structure may be provided, suchas drivers, fairway woods, wood-type hybrid clubs, chipping clubs, andthe like. Any desired loft angles, head weights, lie angles, etc., alsomay be used without departing from the invention, e.g., if the club isdesigned as a 2-wood, 3-wood, 4-wood, 5-wood, 7-wood, 9-wood, 11-wood,etc.; to suit a user's preferences and/or swing characteristics; toprovide the desired launch angle, carry distance, and/or othercharacteristics for the club; etc. Additionally, various different shaftcharacteristics (such as stiffness, flex point, kick point, etc.) may beused to further allow change and control over the club's and the clubhead's feel and characteristics.

As noted above, basalt materials, including basalt fiber-reinforcedmaterials, may be used in any desired wood type golf club structure,including drivers, fairway woods, wood-type hybrid clubs, chippingclubs, and the like. As some more specific and non-limiting examples,basalt materials may be used akin to the use of carbon-fiber materialsas one or more parts of the club head structures described, for example,in U.S. Pat. Nos. 6,406,381; 6,739,983; 6,758,763; and 6,881,159 andU.S. Published Patent Appln. No. 2004/0034986. Each of these patentdocuments is entirely incorporated herein by reference.

C. Example Shaft or Other Elongated Tubular Structures

Another example aspect of this invention relates to golf club shaftmembers (or other tubular members, optionally tapered tubular members).Such members may be constructed in any suitable manner without departingfrom this invention, including in manners that utilize, for example,prior art fiber-reinforced resin and composite production techniques.For example, the shaft may be prepared as a solid or hollow elongatetube wherein at least a portion of the elongate tube comprises basaltmaterial.

In one aspect, as shown in FIG. 6, a golf club shaft 600 may beconstructed as an elongate tube member 602, optionally having a gripelement 604 engaged therewith. As shown in FIG. 6A, the elongate tubemember 602 may have a core layer 606 and at least a first layer 608about the core layer 606. At least one of the core layer 606 and thefirst layer 608 in this example structure contains basalt material. As amore specific example, the first layer 608 in this structure 602contains a basalt material.

As shown in FIG. 6 b, several layers of material may be used to form theelongate tube member 602. The elongate tube 602 may have a core layer610, a first layer 612 about at least a portion of the core layer 610,and a second layer 614 about at least a portion of the core layer 610 orthe first layer 612. At least one of the core layer 610, first layer612, and second layer 614 in this example structure contains basaltfiber.

As still another example, as shown in FIG. 6 c, the elongate tube member602 may be a single solid elongate tube containing basalt fibers.Alternatively, if desired, the tube member 602 of FIG. 6 c may be ahollow tube constructed of a basalt fiber containing material.

The basalt material may be provided used in any suitable or desiredform. For example, basalt material may be formed into fibers, meshes,sheets, webs, fabrics, weaves, textiles, tapes, rovings, prepregs, andthe like and then rolled to form the solid or hollow tapered tubularstructure, like those shown in FIGS. 6 through 6 c. Alternatively,layers of basalt material may be applied by coating a core or previouslayer (e.g., a steel, aluminum, titanium, or other metal containingmaterial tube) with a basalt material.

Each layer may be the same or different without departing from theinvention. For example, the amount of basalt material used, the type ofresin used, or the type of layer structure (e.g., fibers, mesh, sheet,web, fabrics, weaves, textiles, tapes, rovings, prepregs and the like)used may be the same or different in each layer. Also, differentmaterials may be used in the different layers (e.g., one or more metallayers with one or more basalt material layers, etc.). The layers maycomprise the entire length of the tubular structure or a portionthereof.

The fibers may be positioned unidirectional or multidirectional.Generally, when unidirectional, the fibers are aligned along the lengthof the tube or slanted along the length, although other arrangements arepossible without departing from this invention.

The shaft may further contain an outer cover layer containing, forexample, at least one of titanium, steel, stainless steel, aluminum,tungsten, nickel, copper, zinc, chromium, brass, bronze, magnesium, tin,gold, silver, alloys thereof, or metallic matrix composites. Such outercoatings are known in the art.

III. Conclusion

Golf club heads and shafts in accordance with examples of the presentinvention may be incorporated into a set, e.g., sets including one ormore of woods, irons, hybrid type golf clubs, and/or putters. As a morespecific example, aspects of the present invention may be used toprovide a club set with increasing numbered woods and/or iron golfclubs, such as a driver and/or two or more of fairway woods, hybrid typeclubs, a zero iron, a one iron, a two iron, a three iron, a four iron, afive iron, a six iron, a seven iron, an eight iron, a nine iron, a teniron, a pitching wedge, a lob wedge, a gap wedge, a sand wedge, putters,etc. With at least some examples of the present invention, a golfer, aclub designer, and/or a club fitter may select and/or modify theposition of the center of gravity for each golf club to meet theplayer's unique requirements, skill, or playing style.

As is readily apparent from the above description, this invention may beused to include basalt materials, having a wide variety of potentialproperties, in a wide variety of different locations, in a golf clubstructure (e.g., as part of the head, striking face, hosel, shaft, grip,etc.). The basalt material may be used on the club head exterior, on theinterior, on both, and the basalt material may be visible, partiallyvisible, filled, partially filled, hidden, partially hidden, etc.

Aspects of the invention also include the use of basalt in various otheritems requiring high tensile strength and which should not be brittle.Examples include such items as fishing rods, ski poles, knittingneedles, croquet mallets, racquets, baseball bats, billiard cues, toolhandles, etc., and the like.

While the invention has been described with respect to specific examplesincluding presently preferred modes of carrying out the invention, thoseskilled in the art will appreciate that there are numerous variationsand permutations of the above described systems and methods. Thus, thespirit and scope of the invention should be construed broadly as setforth in the appended claims.

1. A golf club comprising a shaft member and a head member wherein atleast one of the shaft member and the head member comprises a basaltmaterial.
 2. A golf club of claim 1 wherein the basalt materialcomprises at least basalt fiber.
 3. A golf club of claim 1 wherein thebasalt material comprises at least one of a grid, mesh, woven member,braided member, or lattice network member.
 4. A golf club of claim 1wherein the basalt material is present in a resin matrix.
 5. A golf clubof claim 4 wherein the resin includes a thermosetting resin.
 6. A golfclub of claim 5 wherein the thermosetting resin is at least one selectedfrom epoxy resin, phenol resin, polyurethane resin, polyester resin, andvinyl ester resin.
 7. A golf club of claim 4 wherein the resin includesa thermoplastic resin.
 8. A golf club of claim 7 wherein thethermoplastic resin is at least one selected from polypropylene resin,polyether ether ketone resin, acrylonitrile-butadiene-styrene resin, andnylon resin.
 9. A golf club of claim 4 wherein the ratio by volume ofresin to basalt is 1:1 or less.
 10. A golf club shaft comprising anelongate tube member wherein the elongate tube member comprises a basaltmaterial.
 11. A golf club shaft of claim 10 wherein the elongate tubemember comprises a core and a first layer surrounding at least a portionof the core, wherein at least one of the core and the first layercomprises the basalt material.
 12. A golf club shaft of claim 11 whereinthe first layer comprises the basalt material.
 13. A golf club shaft ofclaim 10 wherein the elongate tube member comprises a core, a firstlayer surrounding at least a portion of the core, and a second layersurrounding at least a portion of the core, the first layer, or both,wherein at least one of the core, the first layer, and the second layercomprises the basalt material.
 14. A golf club head comprising a clubhead body member, the club head body member comprising a basaltmaterial.
 15. A golf club head according to claim 14 wherein the basaltmaterial forms a major portion of the club head body member.
 16. A golfclub head according to claim 14 wherein the club head body member formsa putter head structure.
 17. A golf club head according to claim 14wherein the club head body member forms an iron golf club headstructure.
 18. A golf club head according to claim 14 wherein the clubhead body member forms a wood golf club head structure.
 19. A golf clubhead according to claim 14 further comprising a ball striking faceengaged with the club head body member.
 20. A golf club head accordingto claim 19 wherein the ball striking face is integrally formed with thebasalt material of the club head body member.
 21. A golf club headaccording to claim 14 wherein the club head body member includes atleast a first body member including the basalt material and a secondbody member engaged with the first body member.
 22. A golf club,comprising: a club head body member constructed, at least in part, froma basalt material; and a shaft member engaged with the club head bodymember.
 23. A golf club according to claim 22 further comprising a ballstriking face integrally formed with the club head body member.
 24. Agolf club according to claim 22 further comprising: a grip memberengaged with the shaft member.
 25. A golf club according to claim 22wherein the basalt material forms a major portion of the club head bodymember.
 26. A golf club according to claim 22 wherein the club head bodymember forms a putter head structure.
 27. A golf club according to claim22 wherein the club head body member forms an iron golf club structure.28. A golf club according to claim 22 wherein the club head body memberforms a wood golf club head structure.
 29. A golf club according toclaim 22 further comprising: a ball striking face including a metal facemember engaged with the club head body member.
 30. A golf club accordingto claim 22 wherein the club head body member includes at least a firstbody member including the basalt material and a second body memberengaged with the first body member.
 31. A method of forming a golf clubhead, comprising: forming a club head body member, at least in part,from a basalt material; and providing a ball striking face on the clubhead body member.
 32. A method according to claim 31 wherein the clubhead body member is formed as a putter head structure.
 33. A methodaccording to claim 31 wherein the club head body member is formed as aniron golf club head structure.
 34. A method according to claim 31wherein the club head body member is formed such that a major portion ofthe club head body member is constructed from the basalt material.
 35. Amethod according to claim 31 wherein the club head body member is formedas a wood golf club head structure.
 36. A method according to claim 31wherein the ball striking face is provided as a metal face memberengaged with the club head body member.
 37. A method according to claim31 wherein the ball striking face is integrally formed with the clubhead body member.
 38. A method according to claim 31 wherein the clubhead body member is formed to include at least a first body memberincluding the basalt material and a second body member engaged with thefirst body member.
 39. A method of forming a golf club, comprising:forming a club head body member, at least in part, from a basaltmaterial; and engaging a shaft member with the club head body member.40. A method according to claim 39 wherein the club head body member isformed to include a ball striking face integrally formed with the clubhead body member.
 41. A method according to claim 39 wherein the clubhead body member is formed as a putter head structure.
 42. A methodaccording to claim 39 wherein the club head body member is formed as aniron golf club structure.
 43. A method according to claim 39 wherein theclub head body member is formed as a wood golf club head structure. 44.A method according to claim 39 further comprising: engaging a ballstriking face with the club head body member.
 45. A method according toclaim 39 wherein the club head body member is formed so as to include atleast a first body member including the basalt material and a secondbody member engaged with the first body member.
 46. A method of forminga golf club, comprising: forming a shaft member, at least in part, froma basalt material; and engaging a club head body member with the shaftmember.
 47. A method according to claim 46 wherein the shaft comprisesan elongate tube formed from at least two layers, at least one layercomprising the basalt material.
 48. A method according to claim 46wherein the shaft is formed from a hollow tube.
 49. A method accordingto claim 46 wherein the shaft is formed from a solid tube.